Enhanced oxygen barrier performance from modification of vinyl alcohol polymers (PVOH) or ethylene vinyl alcohol copolymers (EVOH)

ABSTRACT

Herein are disclosed modified vinyl alcohol polymers (mPVOH), wherein the mPVOH can comprise structure VII:  
                 
 
     and at least one structure comprising structure IX:  
                 
 
     or structure X:  
                 
 
     wherein —R can independently comprise an unsubstituted hydrocarbon moiety comprising at least one alpha hydrogen or a substituted hydrocarbon moiety comprising at least one alpha hydrogen. The mPVOH can be useful in oxygen barrier applications, such as a forming an oxygen barrier layer of a packaging article. Also disclosed are methods of forming mPVOH and methods of using mPVOH to make packaging articles with a superior barrier to entry by atmospheric oxygen.

[0001] The present application claims priority from U.S. patent application Ser. No. 09/851,537, filed May 8, 2001, which claims priority from U.S. patent application Ser. No. 60/205,999, filed May 19, 2000.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention relates generally to the field of high oxygen barrier polymers. More particularly, it concerns a modified vinyl alcohol polymer (mPVOH), or blends comprising the mPVOH, used as an oxygen barrier for food and beverage packaging applications, methods of making the mPVOH, packaging articles comprising the mPVOH, and methods of making the packaging articles.

[0004] 2. Description of Related Art

[0005] Limiting the exposure of oxygen-sensitive products to oxygen maintains and enhances the quality and shelf-life of the product. For instance, by limiting the oxygen transmission from environment into the oxygen sensitive food products in a packaging system, the quality of the food product can be maintained, and food spoilage can be avoided. In addition, high oxygen barrier packaging also keeps the product in inventory longer, thereby reducing costs incurred from waste and restocking.

[0006] Plastics continue to expand into food packaging applications traditionally served by metal and glass materials. An important packaging application area for polymeric materials is in packaging oxygen-sensitive food and beverage products. Polymers used for these applications, either as films or rigid containers, can be classified by their relative permeation to oxygen. It can be desirable to prepare packaging materials from polymers having low oxygen permeation, i.e., so called “gas barrier” polymers. Of the many classes of polymers for such applications, those generally held to be high oxygen barrier materials include polyvinylalcohol (PVOH), poly(ethylene vinyl alcohol) (EVOH), poly(vinylidene chloride) (PVDC), and acrylonitrile polymer (PAN). The barrier polymers generally classified as moderate to intermediate include aromatic nylon and amorphous nylon. Among the high oxygen barrier resins, the use of poly(ethylene vinyl alcohol) (EVOH) copolymers shows the most rapid growth. EVOH is commercially available in several grades with different ratios of ethylene/vinyl alcohol in the polymer chain. Familiar containers comprising an EVOH oxygen barrier include squeezable bottles (e.g. for ketchup or other condiments), shelf-stable entree container, and, more recently, beer bottles. However, the oxygen barrier properties of high barrier polymers, such as EVOH, are still frequently not as high as glasses or metals for a wide range of packaging applications. This performance gap between high barrier polymers and glasses or metals represents a tremendous opportunity in both rigid and flexible packaging applications; this has prompted intensive effort in the field to improve the oxygen barrier performance for EVOH barrier materials.

SUMMARY OF THE INVENTION

[0007] In one embodiment, the present invention relates to a composition, comprising a modified vinyl alcohol polymer (mPVOH), wherein the mPVOH can comprise structure VII:

[0008] and at least one structure comprising structure IX or structure X:

[0009] wherein —R can independently comprise an unsubstituted hydrocarbon moiety comprising at least one alpha hydrogen or a substituted hydrocarbon moiety comprising at least one alpha hydrogen, and R′ can independently comprise an unsubstituted hydrocarbon moiety or a substituted hydrocarbon moiety.

[0010] In another embodiment, the present invention relates to a packaging article, comprising an oxygen barrier layer comprising the mPVOH as given above.

[0011] In a further embodiment, the present invention relates to a method of making an mPVOH comprising an —R moiety comprising an unsubstituted hydrocarbon moiety comprising at least one alpha hydrogen or a substituted hydrocarbon moiety comprising at least one alpha hydrogen, comprising:

[0012] (i) reacting a vinyl alcohol polymer with X—R, wherein —R can comprise —Z—R″, wherein (a) —R″ can comprise an unsubstituted hydrocarbon moiety comprising at least one alpha hydrogen or a substituted hydrocarbon moiety comprising at least one alpha hydrogen; (b) —Z— can be null, —C(═O)—, or

[0013] wherein each —R′″ can independently be —H, an unsubstituted hydrocarbon moiety, or a substituted hydrocarbon moiety; and (c) X—can be (c-i) —C(═O)H, —C(=O)R′ wherein R′ can be an unsubstituted hydrocarbon moiety or a substituted hydrocarbon moiety, —OH, halogen, or —OR′″ when —Z—is null; (c-ii) —OH, -halogen, —OC(═O)R′″, —NR′″2, or —OR′″, when —Z—is —C(═O)—; or (c-iii) null when —Z—is

[0014] to yield an mPVOH comprising at least one structure comprising structure IX or structure X.

[0015] In yet a further embodiment, the present invention relates to a method of forming a packaging article comprising an oxygen barrier layer, comprising:

[0016] (i) forming a composition comprising a modified ethylene vinyl alcohol polymer (mPVOH), as described above, into the packaging article or a layer thereof.

DESCRIPTION OF FIGURES

[0017]FIG. 1 shows the structure of a representative modified vinyl alcohol polymer (mPVOH) according to the present invention, wherein —R is a group containing at least one carbon atom and at least one hydrogen atom, wherein at least one of the hydrogen atoms is an alpha hydrogen.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0018] In general, the present invention relates to modified vinyl alcohol polymers (mPVOH). The mPVOH can comprise a vinyl alcohol group (structure VII):

[0019] and at least one structure comprising structure IX or structure X:

[0020] wherein —R can be a group containing at least one carbon atom and at least one hydrogen atom, wherein at least one of the hydrogen atoms can be an “alpha hydrogen.” The term “alpha hydrogen” refers to a hydrogen atom bonded to a first carbon atom, wherein the first carbon atom can be also bonded to one or more of the following: (i) a second carbon atom which is double-bonded to a third carbon atom; (ii) a second carbon atom which is a member of an aromatic ring; and (iii) a second carbon atom which is bonded to an oxygen atom; and wherein R′ can independently comprise an unsubstituted hydrocarbon moiety or a substituted hydrocarbon moiety

[0021] A number of terms used in the present disclosure and claims have the following meanings:

[0022] “Independently,” as used herein, means that the determination of the value of each one of multiple variables is not contingent on the value of any other one of the multiple variables.

[0023] “Inclusive,” as used herein, means that the values defining the upper bound and the lower bound of a range are included within the range.

[0024] “The balance,” as used herein, means the remainder of the mass, weight, or mole fraction of a composition or collection after accounting for the mass, weight, or mole fraction of enumerated components of the composition or collection.

[0025] “At least,” as used herein, means that a variable has the stated value or a greater value.

[0026] In one embodiment, the present invention can comprise an oxygen barrier composition comprising a modified ethylene vinyl alcohol polymer comprising a pendant oxidizable group. In one embodiment, the modified ethylene vinyl alcohol polymer can comprise structure I:

[0027] wherein x can be an integer greater than or equal to 1, y can be an integer greater than or equal to 0, and z can be an integer greater than or equal to 0; and R can comprise a cycloalkenyl group. In one embodiment, R can have structure II:

[0028] wherein q₁, q₂, q₃, q₄, and r can independently comprise hydrogen, methyl, or ethyl; m can be —(CH₂)_(n)—, wherein n can be an integer from 0 to 4, inclusive; and, when r is hydrogen, at least one of q₁, q₂, q₃, and q₄ can be hydrogen.

[0029] In one embodiment, y can be greater than or equal to 1, and z can be greater than or equal to 1. In another embodiment, the cycloalkenyl group can be cyclohexenyl (i.e. in structure II, n can be 1 and q₁, q₂, q₃, q₄, and r can each be hydrogen).

[0030] An alternative way of defining the polymer of the present invention can be as a polymer, comprising structures IV, V, and VI:

[0031] wherein x can be an integer greater than or equal to 1, y can be an integer greater than or equal to 1, z can be an integer greater than or equal to 1, and R can comprise a cycloalkenyl group. In one embodiment, R can have structure II:

[0032] wherein q₁, q₂, q₃, q₄, and r can independently comprise hydrogen, methyl, or ethyl; m can be —(CH₂)_(n)—, wherein n can be an integer from 0 to 4, inclusive; and, when r is hydrogen, at least one of q₁, q₂, q₃, and q₄ can be also hydrogen.

[0033] In our effort to develop EVOH polymers with superior oxygen barrier properties, we modified the EVOH polymer structure by incorporating a desirable amount of an oxygen scavenging functional group onto EVOH polymer. Hence, “modified ethylene vinyl alcohol polymer” or “modified EVOH” refers to an EVOH polymer into which an oxygen scavenging functional group has been incorporated. An “unmodified EVOH” is an ethylene vinyl alcohol polymer lacking an oxygen scavenging functional group. As a result, a significantly improved oxygen barrier can be achieved by a combination of the inherent physical barrier function of EVOH polymer and an added oxygen scavenging function (active barrier) capable of consuming the fraction of otherwise diffusible ingress oxygen through the EVOH backbone. The combination may be within the modified EVOH molecule, within a blend comprising the modified EVOH and an unmodified EVOH, or both.

[0034] In one embodiment, the structural modification can have a minimum impact on the physical barrier property of EVOH or PVOH. The oxygen scavenging function (active barrier) introduced will be most efficient for enhancing the oxygen barrier performance only if the physical barrier property of EVOH polymer can be largely retained.

[0035] In a modified ethylene vinyl alcohol polymer of the present invention, the weight fraction of the R groups relative to the polymer will typically be in the range of about 1 wt % to about 30 wt %.

[0036] As stated above, the modified ethylene vinyl alcohol polymer can be a component of an oxygen barrier composition. The oxygen barrier composition will often be used to form an oxygen barrier layer of a packaging article. The amount of the modified ethylene vinyl alcohol polymer in the oxygen barrier composition can be from about 1% to about 99%, from about 2% to about 50%, or from about 5% to about 20%, by weight of the composition. The balance of the oxygen barrier composition can comprise additives which are known for use in oxygen barrier compositions or, owing to the presence of oxygen scavenging functional groups, oxygen scavenging compositions.

[0037] Compounds can be added to modify the oxygen barrier functionality of the composition. For example, in one embodiment, the modified EVOH polymers of the invention with a high weight percentage of R groups (i.e. greater than about 10 wt % of the modified EVOH or modified PVOH) can be used to form a miscible blend with an unmodified EVOH polymer, in order to adjust barrier performance, physical properties, and process capability.

[0038] Compounds can be selected to enhance the oxygen scavenging functionality of the modified EVOH polymers in storage, processing into a layer of a packaging article, or use of the packaging article. Such enhancements include, but are not limited to, limiting the rate of oxygen scavenging by the oxygen scavenging groups of the modified EVOH prior to filling of the packaging article with a product, initiating oxygen scavenging by the oxygen scavenging groups of the modified EVOH at a desired time, or limiting the induction period (the period between initiating oxygen scavenging and scavenging of oxygen at a desired rate), among others. These compounds can be added to the oxygen barrier composition comprising the modified ethylene vinyl alcohol polymer, to provide benefits for oxygen scavenging by the oxygen scavenging functional group of the modified ethylene vinyl alcohol polymer.

[0039] In one embodiment, the oxygen barrier composition, an oxygen barrier layer formed from the composition, or a packaging article comprising the oxygen barrier layer, can comprise a transition metal catalyst. Though not to be bound by theory, useful catalysts include those which can readily interconvert between at least two oxidation states. See Sheldon, R. A.; Kochi, J. K.; “Metal-Catalyzed Oxidations of Organic Compounds” Academic Press, New York 1981.

[0040] In one embodiment, the catalyst can be in the form of a salt, with the transition metal selected from the first, second or third transition series of the Periodic Table. Suitable metals include, but are not limited to, manganese, iron, cobalt, nickel, copper, rhodium, and ruthenium. The oxidation state of the metal when introduced need not necessarily be that of the active form. The metal can be iron, nickel, manganese, cobalt or copper. In one embodiment, the metal can be manganese or cobalt; and in another embodiment, the metal can be cobalt. Suitable counterions for the metal include, but are not limited to, chloride, acetate, oleate, stearate, palmitate, 2-ethylhexanoate, neodecanoate or naphthenate. In one embodiment, the salt, the transition metal, and the counterion are either on the U.S. Food and Drug Administration GRAS (generally regarded as safe) list, or exhibit substantially no migration from the packaging article to the product (i.e. less than about 500 ppb, or less than about 50 ppb, in the edible dietary intake (EDI)). In one embodiment, the salt can be cobalt oleate, cobalt stearate, cobalt 2-ethylhexanoate, or cobalt neodecanoate. The metal salt may also be an ionomer, in which case a polymeric counterion can be employed. Such ionomers are well known in the art.

[0041] Typically, the amount of transition metal catalyst may range from 0.001 to 1% (10 to 10,000 ppm) of the oxygen barrier composition, based on the metal content only (excluding ligands, counterions, etc.). In a packaging article, the transition metal catalyst can be formed in the high oxygen barrier layer or in a layer adjacent to the high oxygen barrier layer.

[0042] Another compound that can be added to the oxygen barrier composition can be a photoinitiator, or a blend of different photoinitiators, especially if antioxidants are included to prevent premature oxidation of the oxygen scavenging functional groups of the composition.

[0043] Suitable photoinitiators are well known to those skilled in the art. Specific examples include, but are not limited to, benzophenone, o-methoxybenzophenone, acetophenone, o-methoxy-acetophenone, acenaphthenequinone, methyl ethyl ketone, valerophenone, hexanophenone, α-phenyl-butyrophenone, p-morpholinopropiophenone, dibenzosuberone, 4-morpholinobenzophenone, benzoin, benzoin methyl ether, 4-o-morpholinodeoxybenzoin, p-diacetylbenzene, 4-aminobenzophenone, 4′-methoxyacetophenone, α-tetralone, 9-acetylphenanthrene, 2-acetylphenanthrene, 10-thioxanthenone, 3-acetylphenanthrene, 3-acetylindole, 9-fluorenone, 1-indanone, 1,3,5-triacetylbenzene, thioxanthen-9-one, xanthene-9-one, 7-H-benz[de]anthracen-7-one, benzoin tetrahydropyranyl ether, 4,4′-bis(dimethylamino)-benzophenone, 1′-acetonaphthone, 2′-acetonaphthone, acetonaphthone and 2,3-butanedione, benz[a]anthracene -7,12-dione, 2,2-dimethoxy-2-phenylacetophenone, α,α-diethoxyacetophenone, and α,α-dibutoxyacetophenone, among others. Singlet oxygen generating photosensitizers such as Rose Bengal, methylene blue, and tetraphenyl porphine may also be employed as photoinitiators. Polymeric initiators include poly(ethylene carbon monoxide) and oligo[2-hydroxy-2-methyl-1-[4-(1-methylvinyl)phenyl]propanone].

[0044] Use of a photoinitiator generally provides faster and more efficient initiation of oxygen scavenging by the oxygen scavenging functional groups of the modified ethylene vinyl alcohol polymer. The minimum amount of photoinitiator can vary depending on the photoinitiator used, the wavelength and intensity of ultraviolet light used to initiate, and other factors. In one embodiment, the photoinitiator can be either on the U.S. Food and Drug Administration GRAS (generally regarded as safe) list, or exhibits substantially no migration from the packaging article to the product (i.e. less than 50 ppb in the EDI).

[0045] Photoinitiators that are especially useful in the present invention include benzophenone derivatives containing at least two benzophenone moieties, as described in U.S. Pat. No. 6,139,770. These compounds act as effective photoinitiators to initiate oxygen scavenging activity in oxygen scavenging compositions. Such benzophenone derivatives have a very low degree of extraction from oxygen barrier compositions, which may lead to reduced malodor or off-taste of a packaged food, beverage, or oral pharmaceutical product by extracted photoinitiator.

[0046] A “benzophenone moiety” is a substituted or unsubstituted benzophenone group. Suitable substituents include alkyl, aryl, alkoxy, phenoxy, and alicylic groups contain from 1 to 24 carbon atoms or halides.

[0047] The benzophenone derivatives include dimers, trimers, tetramers, and oligomers of benzophenones and substituted benzophenones.

[0048] The benzophenone photoinitiators are represented by the formula:

A _(a)(B)_(b)

[0049] wherein A can be a bridging group comprising sulfur; oxygen; carbonyl; —SiR″₂—, wherein each R″ can individually comprise alkyl groups containing from 1 to 12 carbon atoms, aryl groups containing 6 to 12 carbon atoms, or alkoxy groups containing from 1 to 12 carbon atoms; —NR′″—, wherein R′″ can be an alkyl group containing 1 to 12 carbon atoms, an aryl group containing 6 to 12 carbon atoms, or hydrogen; or an organic group containing from 1 to 50 carbon atoms; a can be an integer from 0 to 11; B can be a substituted or unsubstituted benzophenone group; and b can be an integer from 2 to 12.

[0050] The bridging group A can be a divalent group, or a polyvalent group with 3 or more benzophenone moieties. The organic group, when present, can be linear, branched, cyclic (including fused or separate cyclic groups), or an arylene group (which can be a fused or non-fused polyaryl group). The organic group can contain one or more heteroatoms, such as oxygen, nitrogen, phosphorous, silicon, or sulfur, or combinations thereof. Oxygen can be present as an ether, ketone, ester, or alcohol.

[0051] The substituents of B, herein R″, when present, can individually comprise alkyl, aryl, alkoxy, phenoxy, or alicylic groups containing from 1 to 24 carbon atoms, or halides. Each benzophenone moiety can have from 0 to 9 substituents. Substituents can be seiected to render the photoinitiator more compatible with the oxygen scavenging composition.

[0052] Examples of such benzophenone derivatives comprising two or more benzophenone moieties include dibenzoyl biphenyl, substituted dibenzoyl biphenyl, benzoylated terphenyl, substituted benzoylated terphenyl, tribenzoyl triphenylbenzene, substituted tribenzoyl triphenylbenzene, benzoylated styrene oligomer (a mixture of compounds containing from 2 to 12 repeating styrenic groups, comprising dibenzoylated 1,1-diphenyl ethane, dibenzoylated 1,3-diphenyl propane, dibenzoylated 1-phenyl naphthalene, dibenzoylated styrene dimer, dibenzoylated styrene trimer, and tribenzoylated styrene trimer), and substituted benzoylated styrene oligomer. In one embodiment, the photoinitiator can be tribenzoyl triphenylbenzene or substituted tribenzoyl triphenylbenzene.

[0053] The amount of photoinitiator can vary. In many instances, the amount will depend on the modified ethylene vinyl alcohol polymer used, the wavelength and intensity of UV radiation used, the nature and amount of antioxidants used, as well as the type of photoinitiator used. The amount of photoinitiator also depends on the intended use of the oxygen barrier layer. For instance, if the photoinitiator-containing component is placed underneath a layer which is somewhat opaque to the radiation used, more initiator may be needed. For most purposes, however, the amount of photoinitiator, when used, will be in the range of 0.01 to 10% by weight of the total oxygen barrier composition.

[0054] Antioxidants may be used in the composition to control scavenging initiation by the oxygen scavenging functional groups of the modified ethylene vinyl alcohol polymer. An antioxidant as defined herein is a material which inhibits oxidative degradation or cross-linking of polymers. Typically, antioxidants are added to facilitate the processing of polymeric materials or prolong their useful lifetime. In relation to this invention, such additives prolong the induction period for oxygen scavenging in the absence of irradiation. Oxygen scavenging by the oxygen scavenging functional groups of the modified ethylene vinyl alcohol polymer in the packaging article can be activated or initiated by exposing the packaging article (and any incorporated photoinitiator) to radiation.

[0055] Antioxidants such as 2,6-di(t-butyl)-4-methylphenol(BHT), 2,2′-methylene-bis(6-t-butyl-p-cresol), triphenylphosphite, tris-(nonylphenyl)phosphite, vitamin E, tetra-bismethylene 3-(3,5-ditertbutyl-4-hydroxyphenyl)-propionate methane, and dilaurylthiodipropionate are suitable for use with this invention.

[0056] The amount of an antioxidant which may be present may also have an effect on the rate of oxygen scavenging by the oxygen scavenging functional groups of the oxygen barrier composition. As mentioned earlier, antioxidants are usually present in compositions comprising an oxidizable organic compound or a structural polymer to prevent oxidation or gelation of the polymers. Typically, they are present in about 0.01 to 1% by weight of the composition. However, additional amounts of antioxidant may also be added to tailor the induction period as described above.

[0057] A structural polymer, such as polyethylene terephthalate (PET), can be included as well. Also, additives which can be included in the oxygen barrier layer include, but are not necessarily limited to, fillers, pigments, dyestuffs, stabilizers, processing aids, plasticizers, fire retardants, and anti-fog agents, among others.

[0058] Any other additives employed normally will not comprise more than 10%, or less than 5%, of the oxygen barrier composition by weight of the composition.

[0059] In another embodiment, the present invention relates to a composition, comprising a modified vinyl alcohol polymer (mPVOH), wherein the mPVOH can comprise structure VII:

[0060] and at least one structure comprising structure IX or structure X:

[0061] wherein —R can independently comprise an unsubstituted hydrocarbon moiety comprising at least one alpha hydrogen or a substituted hydrocarbon moiety comprising at least one alpha hydrogen, and R′ can independently comprise an unsubstituted hydrocarbon moiety or a substituted hydrocarbon moiety.

[0062] The modified vinyl alcohol polymer may also comprise structure VIII:

[0063] In other words, ethylene/vinyl alcohol copolymers, i.e., comprising structure VII and structure VIII, are encompassed by the term “vinyl alcohol polymer,” as used herein. Modified ethylene/vinyl alcohol copolymers, i.e., comprising structure VII, structure VIII, and at least one of structure IX and structure X, are encompassed by the term “modified vinyl alcohol polymer,” as used herein.

[0064] The term “polymer,” as used herein, encompasses homopolymers, copolymers, terpolymers, etc.

[0065] In the definition of —R as used in structure IX and structure X, “an unsubstituted hydrocarbon moiety” refers to moieties consisting of one or more carbon atoms and one or more hydrogen atoms, and “a substituted hydrocarbon moiety” refers to moieties comprising one or more carbon atoms, one or more hydrogen atoms, and one or more atoms of an element or elements other than carbon and hydrogen. Examples of such elements include, but are not limited to, oxygen, sulfur, silicon, and nitrogen, among others. Atoms of elements other than carbon and hydrogen may be present in any part of the moiety, including but not limited to the longest chain of the moiety.

[0066] The term “alpha hydrogen” refers to a hydrogen atom bonded to a first carbon atom, wherein the first carbon atom is also bonded to one or more of the following: (i) a second carbon atom which is double-bonded to a third carbon atom; (ii) a second carbon atom which is a member of an aromatic ring; and (iii) a second carbon atom which is bonded to an oxygen atom.

[0067] In one embodiment, —R can comprise an unsubstituted hydrocarbon moiety having structure II, as defined above. In another embodiment, —R can comprise an unsubstituted hydrocarbon moiety having structure II, as defined above, wherein y can be greater than or equal to 1, z can be greater than or equal to 1, n can be 1, and q₁, q₂, q₃, q₄, and r can be hydrogen.

[0068] In one embodiment, —R can comprise a substituted hydrocarbon moiety comprising structure XI or structure XII:

[0069] The composition may further comprise additional components.

[0070] In one embodiment, the composition further can comprise a transition metal catalyst, as described above. In one embodiment, the transition metal catalyst can be a cobalt salt. In another embodiment, the cobalt salt can comprise cobalt oleate, cobalt stearate, or cobalt neodecanoate.

[0071] In one embodiment, the composition further can comprise a photoinitiator, as described above. In one embodiment, the photoinitiator can comprise benzophenone derivatives containing at least two benzophenone moieties and having the formula A_(a)(B)_(b), as described above. In one embodiment, the benzophenone derivative containing at least two benzophenone moieties can comprise dibenzoyl biphenyl, substituted dibenzoyl biphenyl, benzoylated terphenyl, substituted benzoylated terphenyl, tribenzoyl triphenylbenzene, substituted tribenzoyl triphenylbenzene, benzoylated styrene oligomer, or substituted benzoylated styrene oligomer.

[0072] In one embodiment, the composition further can comprise an antioxidant, as described above. In one embodiment, the antioxidant can comprise 2,6-di(t-butyl)-4-methylphenol(BHT), 2,2′-methylene-bis(6-t-butyl-p-cresol), triphenylphosphite, tris-(nonylphenyl)phosphite, vitamin E, tetra-bismethylene 3-(3,5-ditertbutyl-4-hydroxyphenyl)-propionate methane, or dilaurylthiodipropionate.

[0073] In one embodiment, the composition can be a blend comprising the mPVOH and an oxygen barrier polymer. An “oxygen barrier polymer,” as used herein, is any polymer known in the art which, when formed into a film consisting essentially of the polymer, exhibits low oxygen permeance, herein defined as an oxygen transmission rate equal to or less than about 500 cubic centimeters per square meter (cc/m²) of 1.0 mil thickness film per day per atmosphere at room temperature (about 25° C.). In one embodiment, the oxygen barrier polymer has an oxygen transmission rate of a 1.0 mil thickness film of less than about 50 cc/m² per day per atmosphere at room temperature. Exemplary oxygen barrier polymers include poly(vinyl alcohol) (“unmodified PVOH”), poly(ethylene vinyl alcohol), polyacrylonitrile, polyvinyl chloride, poly(vinylidene dichloride), polyethylene terephthalate, polyamides, or mixtures thereof. In one embodiment, the oxygen barrier polymer is an unmodified PVOH, as described above. In another embodiment, the blend can comprise from about 5 wt % to about 20 wt % mPVOH.

[0074] In another embodiment, the present invention relates to a packaging article, comprising an oxygen barrier composition which can comprise a modified ethylene vinyl alcohol polymer comprising an oxygen scavenging functional group. In one embodiment, the modified ethylene vinyl alcohol can comprise structure I:

[0075] wherein x can be an integer greater than or equal to 1, y can be an integer greater than or equal to 0 (in one embodiment, y can be greater than or equal to 1), and z can be an integer greater than or equal to 0 (in one embodiment, z can be greater than or equal to 1); and R can be a cycloalkenyl group. In one embodiment, R can have structure II:

[0076] wherein q₁, q₂, q₃, q₄, and r can independently comprise hydrogen, methyl, or ethyl; m can be —(CH₂)_(n)—, wherein n can be an integer from 0 to 4, inclusive; and, when r is hydrogen, at least one of q₁, q₂, q₃, and q₄ can be also hydrogen. In one embodiment, R can be cyclohexenyl, i.e. n can be 1 and q₁, q₂, q₃, q₄, and r can each be hydrogen.

[0077] Again, in an alternative definition, the packaging article of the present invention can comprise a polymer, comprising structures IV, V, and VI:

[0078] wherein x can be an integer greater than or equal to 1, y can be an integer greater than or equal to 1, z can be an integer greater than or equal to 1, and R can be a cycloalkenyl group. In one embodiment, R can have structure II:

[0079] wherein q₁, q₂, q₃, q₄, and r can independently comprise hydrogen, methyl, or ethyl; m can be —(CH₂)_(n)—, wherein n can be an integer from 0 to 4, inclusive; and, when r is hydrogen, at least one of q₁, q₂, q₃, and q₄ can be also hydrogen.

[0080] The oxygen barrier composition can be as described above, and can include a transition metal catalyst, a photoinitiator, an antioxidant, an unmodified EVOH polymer, other additives, or any combination thereof In one embodiment, the composition further can comprise an unmodified EVOH polymer.

[0081] Packaging articles typically come in several forms including a single layer film, a multilayer film, a single layer rigid article, or a multilayer rigid article. Typical rigid or semirigid articles include plastic, paper or cardboard cartons or bottles such as juice containers, soft drink containers, thermoformed trays, or cups, which have wall thicknesses in the range of 100 to 1000 micrometers. Typical flexible bags include those used to package many food items, and will likely have thicknesses of 5 to 250 micrometers. The walls of such articles either comprise single or multiple layers of material.

[0082] The oxygen barrier composition can be in the form of an oxygen barrier layer in a single-layer or multilayer packaging article. The additional layers of a multilayer packaging article may further comprise a structural layer or layers, a moisture barrier layer or layers, or a combination thereof.

[0083] In a structural layer, suitable structural polymers include, but are not limited to, polyethylene, low density polyethylene, very low density polyethylene, ultra-low density polyethylene, high density polyethylene, polypropylene, poly(ethylene terephthalate) (PET), poly(ethylene naphthalate (PEN), ethylene-vinyl acetate, ethylene-alkyl (meth)acrylates, ethylene-(meth)acrylic acid, or ethylene-(meth)acrylic acid ionomers.

[0084] In one embodiment, the packaging article can comprise, from the exterior of the packaging article to the interior of the packaging article: an exterior structural layer comprising PET; the oxygen barrier layer comprising the modified EVOH; and an interior structural layer comprising PET. “Exterior” and “interior” structural layers, as used to describe this embodiment, need not form the exterior surface or the interior surface of the packaging article. Also, other layers can be included, either to the exterior of the exterior structural layer, to the interior of the interior structural layer, or between the exterior structural layer and the oxygen barrier layer or between the interior structural layer and the oxygen barrier layer.

[0085] The packaging article comprising the oxygen barrier composition can be used to protect any product from oxygen damage during storage. In one embodiment, the product can be food, beverage, pharmaceuticals, medical products, corrodible metals, or electronic devices. In certain embodiments, the packaging article can be used to maintain an oxygen barrier for a long period of time. In such embodiments, the product can be beer, wine, or other beverages. The packaging article can also be useful to retain carbon dioxide. In one embodiment, the packaging article can be used to package beer, sparkling wine, or soft drinks.

[0086] The packaging article comprising the oxygen barrier composition can comprise a single layer comprising the composition (such layer may be referred to as an “oxygen barrier layer”) or an oxygen barrier layer or layers and additional layers. Single layered packaging articles can be prepared by solvent casting, injection molding, blow molding, or extrusion. Packaging articles with multiple layers are typically prepared using coextrusion, injection molding, blow molding, coating, or lamination.

[0087] The additional layers of a multilayer material may further comprise at least one oxygen barrier layer, i.e. a layer having an oxygen transmission rate equal to or less than 500 cubic centimeters per square meter (cc/m²) per day per atmosphere at room temperature (about 25° C.), wherein the oxygen barrier layer does not comprise a modified EVOH. Typical oxygen barriers comprise poly(ethylene vinyl alcohol), polyacrylonitrile, polyvinyl chloride, poly(vinylidene dichloride), polyethylene terephthalate, silica, polyamides, or mixtures thereof. However, because the oxygen barrier layer comprising the modified ethylene vinyl alcohol polymer inhibits oxygen transmission, the need for a separate oxygen barrier layer can be reduced and may be dispensed with entirely.

[0088] The multilayer packaging article can comprise an oxygen scavenging layer, comprising an oxygen scavenging polymer and, optionally, other additives, such as a photoinitiator, a transition metal catalyst, an antioxidant, a structural polymer, or others, alone or in any combination. The oxygen scavenging layer can be an integral part of the packaging article, or it can be a liner, coating, sealant, gasket, adhesive insert, non-adhesive insert, or fibrous mat insert in the packaging article.

[0089] Other additional layers of the packaging article may include one or more layers which are permeable to oxygen (an “oxygen permeable layer”) and are located on the interior surface of the packaging article, i.e. between the packaged product and the oxygen barrier layer, or the oxygen scavenging layer, if any. In one embodiment, the layers include, in order starting from the outside of the package to the innermost layer of the package, (i) an oxygen barrier layer comprising the modified EVOH of the invention, (ii) an optional oxygen scavenging layer, and (iii) an optional oxygen-permeable layer. Control of the oxygen barrier property of (i) allows regulation of the scavenging life of the oxygen scavenging layer by limiting the rate of oxygen entry to the oxygen scavenging moieties in layer (ii), and thus slows the consumption of oxygen scavenging capacity. Control of the oxygen permeability of layer (iii) allows setting the rate of oxygen scavenging for the overall structure independent of the composition of the scavenging component (ii). Furthermore, layer (iii) can provide a barrier to migration of the components of the high oxygen barrier layer, the scavenging layer, or by-products of scavenging or oxygen barrier activity, into the package interior. Even further, layer (iii) can improve the heat-sealability, clarity, or resistance to blocking of the multilayer packaging article.

[0090] In one embodiment, a moisture barrier layer can be included in the packaging article. A moisture barrier layer can be included to minimize wetting of the oxygen barrier layer of the invention, because the barrier property of a layer comprising EVOH can be somewhat reduced if the layer is wetted. Multiple moisture barrier layers, such as one located to the exterior of the oxygen barrier layer and one located to the interior of the oxygen barrier layer, can be used. Polyolefins (e.g. polyethylene), PET, or both can be used as major components of a moisture barrier layer. PET can be useful in a rigid packaging article application.

[0091] Further additional layers, such as adhesive layers, may also be used. Compositions typically used for adhesive layers include anhydride functional polyolefins and other well-known adhesive layers.

[0092] In another embodiment, the present invention relates to a packaging article, comprising an oxygen barrier layer comprising a modified vinyl alcohol polymer (mPVOH), wherein the mPVOH can comprise structure VII:

[0093] and at least one structure comprising structure IX or structure X:

[0094] wherein —R can independently comprise an unsubstituted hydrocarbon moiety comprising at least one alpha hydrogen or a substituted hydrocarbon moiety comprising at least one alpha hydrogen, and R′ can independently comprise an unsubstituted hydrocarbon moiety or a substituted hydrocarbon moiety.

[0095] The mPVOH has been described above. We have found that the mPVOH possesses both gas barrier properties (provided by the vinyl alcohol main chain) and oxygen scavenging properties (provided by the alpha hydrogen or hydrogens in —R, which are highly reactive with oxygen).

[0096] The packaging article may be in any of the forms described above. Specifically, the packaging article can be in the form of a single layer film, a multilayer film, a single layer rigid article, or a multilayer rigid article.

[0097] The packaging article comprising the oxygen barrier layer may, but need not, comprise additional layers, and the oxygen barrier layer may, but need not, comprise additional components. Exemplary additional components and exemplary additional layers are given below.

[0098] In one embodiment, the packaging article further can comprise a transition metal catalyst in the oxygen barrier layer or a layer adjacent to the oxygen barrier layer. The transition metal catalyst can be as described above.

[0099] In one embodiment, the packaging article further can comprise a photoinitiator in the oxygen barrier layer, as described above.

[0100] In one embodiment, the packaging article further can comprise an antioxidant in the oxygen barrier layer, as described above.

[0101] In one embodiment, the oxygen barrier layer further can comprise an oxygen barrier polymer, as defined above. In one embodiment, the oxygen barrier polymer is an unmodified PVOH. In another embodiment, the oxygen barrier polymer is blended with mPVOH, as described above.

[0102] In one embodiment, the packaging article further can comprise a second oxygen barrier layer not comprising mPVOH, as described above. In one embodiment, the second oxygen barrier layer can comprise poly(ethylene vinyl alcohol) (EVOH), polyvinylalcohol (PVOH), polyacrylonitrile, polyvinyl chloride (PVC), poly(vinylidene dichloride), polyethylene terephthalate (PET), polyamide, silica, metal foil, or mixtures thereof.

[0103] In one embodiment, the packaging article further can comprise a structural layer, as described above. In one embodiment, the structural layer can comprise polyethylene, low density polyethylene, very low density polyethylene, ultra-low density polyethylene, high density polyethylene, polypropylene, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), nylon, polyvinyl chloride, ethylene-vinyl acetate, ethylene-alkyl (meth)acrylates, ethylene-(meth)acrylic acid, or ethylene-(meth)acrylic acid ionomers. In one more embodiment, the structural layer can comprise PET.

[0104] In one embodiment, the packaging article further can comprise a moisture barrier layer, as described above. In one embodiment, the moisture barrier layer can comprise polyethylene, polyethylene terephthalate (PET), or a mixture thereof.

[0105] In one embodiment, the packaging article further can comprise an oxygen scavenging layer, as described above. In one embodiment, the oxygen scavenging layer can be a liner, coating, sealant, gasket, adhesive insert, non-adhesive insert, or fibrous mat insert in the packaging article.

[0106] In another embodiment, the present invention can be directed to a method of making a modified ethylene vinyl alcohol polymer (EVOH) comprising an oxygen scavenging functional group. In one embodiment, the modified EVOH can comprise

[0107] wherein x can be an integer greater than or equal to 1, y can be an integer greater than or equal to 0 (in one embodiment, y can be greater than or equal to 1), and z can be an integer greater than or equal to 0 (in one embodiment, z can be greater than or equal to 1); and R can be a cycloalkenyl group. In one embodiment, R can have structure II:

[0108] wherein q₁, q₂, q₃, q₄, and r can independently comprise hydrogen, methyl, or ethyl; m can be —(CH₂)_(n)—, wherein n can be an integer from 0 to 4, inclusive; and, when r is hydrogen, at least one of q₁, q₂, q₃, and q₄ can be also hydrogen. In one embodiment, n can be 1 and q₁, q₂, q₃, q₄, and r can each be hydrogen.

[0109] An alternative way of defining the modified EVOH can be as a polymer, comprising structures IV, V, and VI:

[0110] wherein x can be an integer greater than or equal to 1, y can be an integer greater than or equal to 1, z can be an integer greater than or equal to 1, and R can be a cycloalkenyl group. In one embodiment, R can have structure II:

[0111] wherein q₁, q₂, q₃, q₄, and r can independently comprise hydrogen, methyl, or ethyl; m can be —(CH₂)_(n)—, wherein n can be an integer from 0 to 4, inclusive; and, when r is hydrogen, at least one of q₁, q₂, q₃, and q₄ can be also hydrogen.

[0112] The method can comprise (i) providing (a) an ethylene vinyl alcohol copolymer and (b) an aldehyde comprising an olefinic or benzylic group. In one embodiment, the aldehyde can have structure III:

[0113] wherein q₁, q₂, q₃, q₄, and r can independently comprise hydrogen, methyl, or ethyl; m can be —(CH₂)_(n)—, wherein n can be an integer from 0 to 4, inclusive; and, when r is hydrogen, at least one of q₁, q₂, q₃, and q₄ can be also hydrogen. The method also can comprise using (c) a catalyst; and

[0114] (ii) reacting the ethylene vinyl alcohol copolymer and the aldehyde in the presence of the catalyst under temperature and pressure sufficient to form the modified ethylene vinyl alcohol polymer.

[0115] The providing step involves the combination of the ethylene vinyl alcohol copolymer, the aldehyde, and the catalyst.

[0116] The ethylene vinyl alcohol copolymer can be from any source and have any proportion of ethylene and vinyl alcohol units. Polyvinylalcohol is within the scope of “ethylene vinyl alcohol copolymer” with regard to this embodiment of the present invention. It should be noted that the lower the proportion of vinyl alcohol units in the copolymer, the lower the proportion of vinyl acetal units that can be formed in the method. However, if very high proportions of vinyl acetal units are formed, the physical barrier properties characteristic to EVOH polymer may be impaired. This can be remedied by forming a miscible blend of the modified EVOH polymers with a high proportion of vinyl acetal units and unmodified EVOH polymers as described above, which provides a desirable physical barrier to oxygen entry and also efficient oxygen scavenging performance. Even if the physical barrier properties of the modified EVOH are adequate, a blend with an unmodified EVOH polymer is still within the scope of the invention.

[0117] Typical commercially-available ethylene vinyl alcohol copolymers comprise from about 27 mole % to about 48 mole % ethylene, with the balance being vinyl alcohol. Optionally, poly(vinyl alcohol) can also be used as the starting material to incorporate the oxygen scavenging functional group in forming the oxygen barrier composition. Such commercially-available ethylene/vinyl alcohol copolymers or poly(vinyl alcohol) polymer have proportions of vinyl alcohol units that can yield desirable proportions of vinyl acetal units upon performance of the method.

[0118] Regarding the aldehyde, in one embodiment, in structure III, n can be 1, and q₁, q₂, q₃, q₄, and r are each hydrogen; i.e. the aldehyde can be a tetrahydrobenzaldehyde (THBE).

[0119] The catalyst can be any catalyst known to promote the condensation reaction of the aldehyde and the EVOH copolymer. Typically, the catalyst can be a mineral acid, such as hydrochloric acid, hydrofluoric acid, a transition metal catalyst, sulfuric acid, or toluene sulfonic acid. In one embodiment, the catalyst can be sulfuric acid. A typical concentration of catalyst can be 2 parts by weight per 100 parts of the EVOH copolymer, although other concentrations that lead to a desired degree of modification of the EVOH copolymer can be used.

[0120] After the EVOH copolymer, the aldehyde, and the catalyst are combined, the reaction can take place. The reaction proceeds by the catalyzed condensation reaction between the available 1,3-diol structure units from EVOH and the aldehyde. As a result, the oxygen scavenging functional group can be attached to the EVOH polymer through an acetal linkage. The reaction can occur either as a batch process or a continuous process, in view of the description below.

[0121] Typically, the reaction takes place by either a solvent or suspension process. In the solvent process, the EVOH copolymer, the aldehyde, and the catalyst are dissolved in an appropriate solvent, such as acetic acid, water, ethanol, or a mixture thereof.

[0122] In the suspension process, the EVOH copolymer, the aldehyde, and the catalyst are provided along with a suspending agent such as polyvinyl alcohol, starch, gelatin, calcium phosphate, poly(acrylic acid) salts, gum arabic, or gum tragacanth, can be used. In one embodiment, the suspending agent can be polyvinyl alcohol. The suspending agent allows the formation of droplets of the EVOH copolymer and the aldehyde, and thus reduces the need for an organic solvent.

[0123] Alternatively, the reaction can take place in a melt by a bulk process, or by a reactive extrusion process.

[0124] The reaction can take place at any temperature conducive to the condensation reaction.

[0125] If the reaction takes place in a solvent or a suspension, the pressure can be at any pressure of about 1 atm or greater, but conveniently the reaction vessel can be in equilibrium with atmospheric pressure and the pressure can be about 1 atm.

[0126] Typically, upon completion of the reaction, the mineral acid catalyst can be neutralized by the addition of an equivalent or excess amount of a neutralizing agent, such as sodium acetate.

[0127] The result of the reaction is a polymer comprising a modified EVOH polymer, as well as by-products which may include unreacted aldehyde, salts generated by neutralization of the mineral acid, and condensation by-products, typically water. Any such by-products can be removed, if desired, by any appropriate technique known in the art, such as evaporation under heat or vacuum.

[0128] Another technique by which the modified EVOH can be made can be adapted from a technique for the synthesis of EVOH. Ethylene vinyl acetate copolymer (EVA) can be readily made by the polymerization of ethylene and vinyl acetate, using techniques known in the art. Thereafter, EVOH can be generated by hydrolyzing EVA in an aqueous solution. Appropriate temperature, pressure, and other parameters of the hydrolysis reaction are known to one of skill in the art.

[0129] According to this embodiment, the technique for the synthesis of the modified EVOH follows the above process until EVA is formed. Thereafter, when hydrolysis is performed on the EVA in aqueous solution, generating EVOH, the aldehyde, such as THBE, can be subsequently added to the EVOH solution and the conversion to the modified EVOH can be performed before the EVOH is purified from the solution.

[0130] In one embodiment, the present invention relates to a method of making a modified vinyl alcohol polymer (mPVOH) comprising an —R moiety comprising an unsubstituted hydrocarbon moiety comprising at least one alpha hydrogen or a substituted hydrocarbon moiety comprising at least one alpha hydrogen, comprising:

[0131] (i) reacting a vinyl alcohol polymer with X—R, wherein —R can comprise —Z—R″, wherein (a) —R″ can comprise an unsubstituted hydrocarbon moiety comprising at least one alpha hydrogen or a substituted hydrocarbon moiety comprising at least one alpha hydrogen; (b) —Z—can be null, —C(═O)—, or

[0132] wherein each —R′″ can independently be —H, an unsubstituted hydrocarbon moiety, or a substituted hydrocarbon moiety; and (c) X—can be (c-i) —C(═O)H, —C(═O)R′ wherein R′ can be an unsubstituted hydrocarbon moiety or a substituted hydrocarbon moiety, —OH, -halogen, or —OR′″ when —Z—is null; (c-ii) —OH, -halogen, —OC(═O)R′″, —NR′″2, or —OR′″, when —Z—is —C(═O)—; or (c-iii) null when —Z—is

[0133] to yield an mPVOH comprising at least one structure comprising structure IX or structure X:

[0134] The vinyl alcohol polymer, the —R moiety, and the —R″ moiety are as described above. Any polymer containing structure VII is a “vinyl alcohol polymer” in this embodiment. The term “X—” refers to any moiety which fills the unfilled valences of the —R moiety.

[0135] In the case wherein —Z— in the X—R compound is

[0136] i.e., the X—R compound is an epoxide, R— in structure IX will typically have a structure

[0137] wherein the unfilled valence is bonded to the vinyl alcohol oxygen shown in structure IX. It is possible that the hydroxyl group of R in this case may react with other epoxide groups; such a reaction, and the product thereof, are within the scope of the present claims.

[0138] The reaction can be performed under any conditions wherein one of ordinary skill in the art would consider the reaction between a vinyl alcohol unit of a vinyl alcohol polymer and an X—R molecule to be likely to occur. In one embodiment, the reaction can be performed in the presence of a catalyst comprising hydrochloric acid, hydrofluoric acid, a transition metal catalyst, sulfuric acid, or toluene sulfonic acid, as described above.

[0139] The reaction may be carried out as any one of a solution process, a bulk process, a suspension process, or a melt process, as described above.

[0140] After the reaction has occurred, the mPVOH may be processed to reduce the concentrations of unmodified PVOH, reaction by-products, residual reactants, and solvents, if any, present in the reaction mixture.

[0141] After mPVOH is prepared, and optionally processed, in one embodiment, the method further can comprise blending the mPVOH with an oxygen barrier polymer. In one embodiment, the oxygen barrier polymer is an unmodified PVOH.

[0142] In another embodiment, the present invention relates to a method of forming a packaging article with at least an oxygen barrier layer, comprising:

[0143] (i) providing an oxygen barrier composition comprising a modified ethylene vinyl alcohol polymer comprising the structure I:

[0144] wherein x can be an integer greater than or equal to 1, y can be an integer greater than or equal to 0 (for example, greater than or equal to 1), and z can be an integer greater than or equal to 0 (for example, greater than or equal to 1); and R can be a cycloalkenyl group. In one embodiment, R can have structure II:

[0145] wherein q₁, q₂, q₃, q₄, and r can independently comprise hydrogen, methyl, or ethyl; m can be —(CH₂)_(n)—, wherein n can be an integer from 0 to 4, inclusive; and, when r is hydrogen, at least one of q₁, q₂, q₃, and q₄ can be also hydrogen; and

[0146] (ii) forming the oxygen barrier composition into a layer or layers of the packaging article.

[0147] Again, the modified EVOH can also be defined as a polymer, comprising structures IV, V, and VI:

[0148] wherein x can be an integer greater than or equal to 1, y can be an integer greater than or equal to 1, z can be an integer greater than or equal to 1, and R can be a cycloalkenyl group. In one embodiment, R can have structure II:

[0149] wherein q₁, q₂, q₃, q₄, and r can independently comprise hydrogen, methyl, or ethyl; m can be —(CH₂)_(n)—, wherein n can be an integer from 0 to 4, inclusive; and, when r is hydrogen, at least one of q₁, q₂, q₃, and q₄ can be also hydrogen.

[0150] The modified ethylene vinyl alcohol polymer, the oxygen barrier composition, and the packaging article are as described above. In one embodiment, the modified ethylene vinyl alcohol polymer can be chosen such that n is 1 and q₁, q₂, q₃, q₄, and r can be hydrogen.

[0151] The forming step can be by any appropriate technique depending on the oxygen barrier composition, the packaging article, and other parameters. As mentioned above, single layered packaging articles typically can be prepared by solvent casting, injection molding, blow molding, or extrusion, among others. Packaging articles with multiple layers are typically prepared using coextrusion, injection molding, blow molding, stretch blow molding, coating, or lamination, among others.

[0152] If a transition metal catalyst is to be included in the packaging article to catalyze oxygen scavenging by the oxygen scavenging functional groups of the oxygen barrier composition, the forming step can comprise forming a transition metal catalyst into the oxygen barrier layer or a layer adjacent to the oxygen barrier layer of the packaging article.

[0153] The oxygen barrier composition can also comprise a photoinitiator, an antioxidant, a structural polymer, or other additives as described above. In one embodiment, the oxygen barrier composition can comprise a blend of the modified EVOH and an unmodified EVOH.

[0154] In addition to the oxygen barrier layer, the packaging article to be formed can comprise other layers, such as an oxygen barrier layer not comprising the modified EVOH, a structural layer, an oxygen scavenging layer, or an oxygen-permeable layer in the packaging article to the interior of the oxygen scavenging layer. Depending on the desired form of the packaging article, the forming step can comprise forming the packaging article as a single layer film, a multilayer film, a single layer rigid article, or a multilayer rigid article.

[0155] In another embodiment, the present invention relates to a method of forming a packaging article comprising an oxygen barrier layer, comprising:

[0156] (i) forming a composition comprising a modified vinyl alcohol polymer (mPVOH), wherein the mPVOH can comprise structure VII:

[0157]  and at least one structure comprising structure IX or structure X:

[0158] wherein —R can independently comprise an unsubstituted hydrocarbon moiety comprising at least one alpha hydrogen or a substituted hydrocarbon moiety comprising at least one alpha hydrogen, and R′ can independently comprise an unsubstituted hydrocarbon moiety or a substituted hydrocarbon moiety, into the packaging article or a layer thereof.

[0159] The mPVOH is as described above. The composition comprising mPVOH may further comprise additional components, as described above. Exemplary additional components include, but are not limited to, photoinitiators, antioxidants, and oxygen barrier polymers, among others, as described above.

[0160] The method may further comprise forming one or more additives into the oxygen barrier layer or another layer of the packaging article.

[0161] In one embodiment, the method further can comprise forming a transition metal catalyst into the oxygen barrier layer or a layer adjacent to the oxygen barrier layer of the packaging article.

[0162] The method may further comprise forming additional layers of the packaging article.

[0163] In one embodiment, the method further can comprise forming a second oxygen barrier layer not comprising mPVOH in the packaging article.

[0164] In one embodiment, the method further can comprise forming a structural layer in the packaging article. In one embodiment, the structural layer can comprise PET.

[0165] In one embodiment, the method further can comprise forming a moisture barrier layer in the packaging article.

[0166] In one embodiment, the method further can comprise forming an oxygen scavenging layer in the packaging article.

[0167] A wide variety of packaging articles can be formed by this method. In one embodiment, the method can comprise forming a multilayer rigid container comprising, from exterior to interior: a structural layer comprising PET; the oxygen barrier layer; and a structural layer comprising PET. The method can be used to form the packaging article as a single layer film, a multilayer film, a single layer rigid article, or a multilayer rigid article.

[0168] The following examples are included to demonstrate particular embodiments of the invention. It should be appreciated by those of skill in the art that the techniques disclosed in the examples which follow represent techniques discovered by the inventor to function well in the practice of the invention. However, those of skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments which are disclosed and still obtain a like or similar result without departing from the spirit and scope of the invention.

EXAMPLES

[0169] In the following examples, the EVOH used (Eval F101A, from Evalca Inc.) contained 32% mole ethylene content and had a melt index of 3.6 g/10 min at 210° C. and a loading of 2.16 kg, and a melting point of 183° C. For synthesis of the modified EVOH, EVOH (Eval F 101A) was used as is. For compounding and extrusion, EVOH was dried at 90° C. for 12 hours under vacuum to remove the moisture. The tetrahydrobenzaldehyde was obtained from Diacel Corp. of Japan.

Example 1

[0170] To a reactor equipped with a mechanical stirrer, nitrogen inlet and external heating, 250 parts water, 500 parts acetic acid, 500 parts ethyl alcohol, and 100 parts poly(ethylene vinyl alcohol) (68% alcohol content) were charged. The mixture was heated to gentle reflux at 90° C. to allow the polymer to completely dissolve in the solution. Then, 5 parts tetrahydrobenzaldehyde were charged. This was followed by charging 2 parts sulfuric acid drop-wise into the content. The reaction content was maintained at 90° C. under stirring for 6 hours. At the end of the reaction, the solution was allowed to cool to room temperature overnight. The solution was neutralized by adding 60 mL of sodium acetate solution (25%). It was stirred for about 1 hour. The reaction solution was slowly added into 4 L acetone under vigorous stirring to result in precipitation. The product was washed in acetone for 2 hours under vigorous agitation, and the product was collected in a white fibrous form by filtration. The product was rinsed with 2×1 L acetone. The product obtained from the rinsing step was re-dissolved in 1.8 L ethyl alcohol and the obtained solution was added slowly into 4 L acetone to precipitate the product. The product was typically dried at 50° C. in a vacuum oven for 24 hr. This gave 111 g product: Tg=60° C.; Tm=133° C. (DSC, 10° C./min).

Example 2

[0171] Similarly to Example 1,500 parts water, 500 parts ethyl alcohol, 100 parts poly(ethylene vinyl alcohol) (68% alcohol content), and 10 parts tetrahydrobenzaldehyde were used. This gave 113 g product: Tg=60° C.; Tm=110° C. (DSC, 10° C./min).

Example 3

[0172] Similarly to Example 1,500 parts water, 500 parts ethyl alcohol, 100 parts poly(ethylene vinyl alcohol) (68% alcohol content), and 20 parts tetrahydrobenzaldehyde were used. This gave 120 g product: Tg=64° C. (DSC, 10° C./min).

Example 4

[0173] Similarly to Example 1,500 parts water, 500 parts ethyl alcohol, 100 parts poly(ethylene vinyl alcohol) (68% alcohol content), and 30 parts tetrahydrobenzaldehyde were used. This gave 137 g product: Tg=60° C. (DSC,10° C./min).

Example 5

[0174] Similarly to Example 1,500 parts water, 500 parts ethyl alcohol, 100 parts poly(ethylene vinyl alcohol) (68% alcohol content), and 40 parts tetrahydrobenzaldehyde were used. This gave 143 g product: Tg=65° C. (DSC, 10° C./min).

Example 6

[0175] Similarly to Example 1,500 parts water, 500 parts ethyl alcohol, 100 parts poly(ethylene vinyl alcohol) (68% alcohol content), and 60 parts tetrahydrobenzaldehyde were used. This gave 127 g product: Tg=65° C. (DSC, 10° C./min).

Example 7

[0176] Film Casting

[0177] The polymer obtained according to any one of Examples 1-6 was converted into a strand on a Hakke twin screw extruder at temperature range of 170° C. to 200° C., then palletized on a strand cutter. A series of dry blends were prepared from the obtained pellets of modified ethylene-vinyl alcohol copolymer, ethylene-vinyl alcohol and cobalt masterbatch (containing 1 wt % tribenzoyl triphenylbenzene and 0.5 wt % cobalt as cobalt oleate in EVOH) by mixing in a polyethylene bag. The blends differed in the weight ratio of modified ethylene-vinyl alcohol copolymer, ethylene-vinyl alcohol (Eval F101A) and masterbatch, with typical masterbatch concentration from 5-20 wt %. The dry blends were compounded on a Hakke twin screw extruder at temperature range of 170° C. to 220° C. at 30 rpm screw speed (Table 1). The temperature for film casting on Randcastle extruder was about 220° C. Exemplary blend compositions are given below. TABLE 1 Blend Composition Modified Cobalt EVOH, EVOH* Masterbatch Concentration Material % by wt % by wt % by wt ppm Sample A 100  0  0   0 Sample B  70 20 10  500 Sample C  60 20 20 1000

Example 8

[0178] Oxygen Permeability

[0179] Films prepared according to Example 7 were tested for oxygen permeability using a Mocon Ox-Trans 2/20 ML system at 23° C. Nitrogen containing 2% hydrogen was used as carrier gas to flush both sides of the film at 10 cc/min flow rate for one to three days before testing. Air was used as test gas at 10 cc/min flow rate. The oxygen permeability was measured in cubic centimeters per m² per 24 hours. The films were tested typically within a few days after being made. TABLE 2 Oxygen Permeability vs. Layer Composition in Multilayer Films Layer Individual Layer Modified EVOH in Co concentration O₂ Transmission Rate** Sample Composition Thickness (mil) core layer (% wt.) core-layer (ppm) cc/(m².Day) Sample D PE/Sample A*/PE 1.0/1.0/1.0 0 0 0.59 Sample E PE/Sample B*/PE 1.0/1.0/1.0 20 500 0 Sample F PE/Sample C*/PE 1.0/1.0/1.0 20 1000 0

Conclusions

[0180] One approach in achieving improved oxygen barrier performance can be to blend in a minor amount of a modified EVOH according to the present invention with a commercially available EVOH copolymer in the presence of an oxidation catalyst. Based on the results shown in Table 2, it is evident that the presence of a modified EVOH according to the present invention in the EVOH barrier layer can significantly enhance the oxygen barrier performance. Since the EVOH is only partially modified, the modified EVOH still maintained the characteristics of EVOH, and hence, was sufficiently compatible with EVOH copolymer. This ensured the desired dispersion of oxygen scavenging EVOH (modified EVOH) in the EVOH matrix and maintained desirable optical clarity of the extruded films. This approach did not require the retention of a physical barrier property (passive barrier) from the modified EVOH since the unmodified EVOH in the blend provided the passive barrier property. The main attribute from the relatively low amount of modified EVOH in the blend is the scavenging action in eliminating the fugitive oxygen, which enhanced the overall oxygen barrier property of the blend composition in the barrier layer.

[0181] An alternative approach can be to use the modified EVOH as the major component in the barrier layer structure, without additional commercial EVOH. In this case, the enhanced oxygen barrier performance was most effectively achieved when the modification level was kept at a relatively low level (data not shown). This may be due to a structural disruption caused by high level modification, which leads to detrimental effects on the passive oxygen barrier property characteristics of EVOH; this structural disruption was suggested by the DSC analysis of the modified EVOH (Examples 1-6). A significant depression in crystallinity (represented by decreased Tg) was observed from the high level modification of EVOH. In Example 5, a totally amorphous polymer was obtained when 100 parts EVOH were modified by 40 parts tetrahydrobenzaldehyde. The crystalline characteristic of EVOH is generally held by those of ordinary skill in the art at the present time to be a major contributor to the high oxygen barrier property of EVOH.

[0182] All of the compositions and methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods of this invention have been described in terms of particular embodiments, it will be apparent to those of skill in the art that variations may be applied to the compositions and methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and scope of the invention. More specifically, it will be apparent that certain agents which are chemically related may be substituted for the agents described herein while the same or similar results would be achieved. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the invention as defined by the appended claims. 

What is claimed is:
 1. A composition, comprising a modified vinyl alcohol polymer (mPVOH), wherein the mPVOH comprises structure VII:

and at least one structure comprising structure IX or structure X:

wherein —R can independently comprise an unsubstituted hydrocarbon moiety comprising at least one alpha hydrogen or a substituted hydrocarbon moiety comprising at least one alpha hydrogen, and R′ can independently comprise an unsubstituted hydrocarbon moiety or a substituted hydrocarbon moiety.
 2. The composition of claim 1, wherein the mPVOH further comprises structure VIII:


3. The composition of claim 1, wherein —R comprises an unsubstituted hydrocarbon moiety having structure II:

wherein q₁, q₂, q₃, q₄, and r independently comprise hydrogen, methyl, or ethyl; m is —(CH₂)_(n)—, wherein n is an integer from 0 to 4, inclusive; and, when r is hydrogen, at least one of q₁, q₂, q₃, and q₄ is also hydrogen.
 4. The composition of claim 3, wherein y is greater than or equal to 1, z is greater than or equal to 1, n is 1, and q₁, q₂, q₃, q₄, and r are hydrogen.
 5. The composition of claim 1, wherein —R comprises a substituted hydrocarbon moiety comprising structure XI or structure XII:


6. The composition of claim 1, further comprising a transition metal catalyst.
 7. The composition of claim 6, wherein the transition metal catalyst is a cobalt salt.
 8. The composition of claim 7, wherein the cobalt salt comprises cobalt oleate, cobalt stearate, or cobalt neodecanoate.
 9. The composition of claim 1, further comprising a photoinitiator.
 10. The composition of claim 1, wherein the composition is a blend comprising the mPVOH and an oxygen barrier polymer.
 11. The composition of claim 10, wherein the oxygen barrier polymer is an unmodified PVOH.
 12. The composition of claim 10, wherein the blend comprises from about 5 wt % to about 20 wt % mPVOH.
 13. A packaging article, comprising: an oxygen barrier layer comprising a modified vinyl alcohol polymer (mPVOH), wherein the mPVOH comprises structure VII:

 and at least one structure comprising structure IX or structure X:

wherein —R can independently comprise an unsubstituted hydrocarbon moiety comprising at least one alpha hydrogen or a substituted hydrocarbon moiety comprising at least one alpha hydrogen, and R′ can independently comprise an unsubstituted hydrocarbon moiety or a substituted hydrocarbon moiety.
 14. The packaging article of claim 13, wherein the mPVOH further comprises structure VIII:


15. The packaging article of claim 13, wherein —R comprises an unsubstituted hydrocarbon moiety having structure II:

wherein q₁, q₂, q₃, q₄, and r independently comprise hydrogen, methyl, or ethyl; m is —(CH₂)_(n)—, wherein n is an integer from 0 to 4, inclusive; and, when r is hydrogen, at least one of q₁, q₂, q₃, and q₄ is also hydrogen.
 16. The packaging article of claim 15, wherein y is greater than or equal to 1, z is greater than or equal to 1, n is 1, and q₁, q₂, q₃, q₄, and r are hydrogen.
 17. The packaging article of claim 13, wherein —R comprises a substituted hydrocarbon moiety comprising structure XI or structure XII:


18. The packaging article of claim 13, further comprising a transition metal catalyst in the oxygen barrier layer or a layer adjacent to the oxygen barrier layer.
 19. The packaging article of claim 18, wherein the transition metal catalyst is a cobalt salt.
 20. The packaging article of claim 19, wherein the cobalt salt comprises cobalt oleate, cobalt stearate, or cobalt neodecanoate.
 21. The packaging article of claim 13, further comprising a photoinitiator in the oxygen barrier layer.
 22. The packaging article of claim 13, wherein the oxygen barrier layer further comprises an oxygen barrier polymer, wherein the oxygen barrier polymer is blended with the mPVOH.
 23. The packaging article of claim 22, wherein the oxygen barrier polymer is an unmodified PVOH.
 24. The packaging article of claim 22, wherein the oxygen barrier layer contains from about 5 wt % to about 20 wt % mPVOH and the balance is the oxygen barrier polymer.
 25. The packaging article of claim 13, further comprising a structural layer.
 26. The packaging article of claim 25, wherein the structural layer comprises polyethylene, low density polyethylene, very low density polyethylene, ultra-low density polyethylene, high density polyethylene, polypropylene, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), nylon, polyvinyl chloride, ethylene-vinyl acetate, ethylene-alkyl (meth)acrylates, ethylene-(meth)acrylic acid, or ethylene-(meth)acrylic acid ionomers.
 27. The packaging article of claim 13, further comprising a moisture barrier layer.
 28. The packaging article of claim 27, wherein the moisture barrier layer comprises polyethylene, polyethylene terephthalate (PET), or a mixture thereof.
 29. The packaging article of claim 13, wherein the packaging article is in the form of a single layer film, a multilayer film, a single layer rigid article, or a multilayer rigid article.
 30. A method of making a modified vinyl alcohol polymer (mPVOH) comprising an —R moiety comprising an unsubstituted hydrocarbon moiety comprising at least one alpha hydrogen or a substituted hydrocarbon moiety comprising at least one alpha hydrogen, comprising: (i) reacting a vinyl alcohol polymer with X—R, wherein —R can comprise —Z—R″, wherein (a) —R″ can comprise an unsubstituted hydrocarbon moiety comprising at least one alpha hydrogen or a substituted hydrocarbon moiety comprising at least one alpha hydrogen; (b) —Z— can be null, —C(═O)—, or

wherein each —R′″ can independently be —H, an unsubstituted hydrocarbon moiety, or a substituted hydrocarbon moiety; and (c) X— can be (c-i) —C(═O)H, —C(═O)R′ wherein R′ can be an unsubstituted hydrocarbon moiety or a substituted hydrocarbon moiety, —OH, -halogen, or —OR′″ when —Z— is null; (c-ii) —OH, -halogen, —OC(═O)R′″, —NR′″2, or —OR′″, when —Z— is —C(═O)—; or (c-iii) null when —Z— is

to yield an mPVOH comprising at least one structure comprising structure IX or structure X:


31. The method of claim 30, wherein —R comprises an unsubstituted hydrocarbon moiety having structure II:

wherein q₁, q₂, q₃, q₄, and r independently comprise hydrogen, methyl, or ethyl; m is —(CH₂)_(n)—, wherein n is an integer from 0 to 4, inclusive; and, when r is hydrogen, at least one of q₁, q₂, q₃, and q₄ is also hydrogen.
 32. The method of claim 31, wherein y is greater than or equal to 1, z is greater than or equal to 1, n is 1, and q₁, q₂, q₃, q₄, and r are hydrogen.
 33. The method of claim 30, wherein —R comprises a substituted hydrocarbon moiety comprising structure XI or structure XII:


34. The method of claim 30, wherein the reaction is performed in the presence of a catalyst comprising hydrochloric acid, hydrofluoric acid, a transition metal catalyst, sulfuric acid, or toluene sulfonic acid.
 35. The method of claim 30, wherein the reaction is carried out as a solution process, a bulk process, a suspension process, or a melt process.
 36. The method of claim 30, further comprising blending the mPVOH with an oxygen barrier polymer.
 37. The method of claim 36, wherein the oxygen barrier polymer is an unmodified PVOH.
 38. A method of forming a packaging article comprising an oxygen barrier layer, comprising: (i) forming a composition comprising a modified vinyl alcohol polymer (mPVOH), wherein the mPVOH comprises structure VII:

 and at least one structure comprising structure IX or structure X:

wherein —R can independently comprise an unsubstituted hydrocarbon moiety comprising at least one alpha hydrogen or a substituted hydrocarbon moiety comprising at least one alpha hydrogen, and R′ can independently comprise an unsubstituted hydrocarbon moiety or a substituted hydrocarbon moiety, into the packaging article or a layer thereof.
 39. The method of claim 38, wherein the mPVOH further comprises structure (VIII):


40. The method of claim 38, wherein the forming step comprises forming a transition metal catalyst into the oxygen barrier layer or a layer adjacent to the oxygen barrier layer of the packaging article.
 41. The method of claim 38, wherein the oxygen barrier composition further comprises a photoinitiator.
 42. The method of claim 38, wherein the oxygen barrier composition comprises a blend of mPVOH and an oxygen barrier polymer.
 43. The method of claim 42, wherein the oxygen barrier polymer is an unmodified PVOH.
 44. The method of claim 42, wherein the blend comprises from about 5 wt % to about 20 wt % mPVOH.
 45. The method of claim 38, wherein the forming step further comprises forming a structural layer in the packaging article.
 46. The method of claim 45, wherein the structural layer comprises PET.
 47. The method of claim 38, wherein the forming step further comprises forming a moisture barrier layer in the packaging article.
 48. The method of claim 38, wherein the forming step comprises forming the packaging article as a single layer film, a multilayer film, a single layer rigid article, or a multilayer rigid article. 